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Spline Broaching

Broaching is a machining process that removes metal using a row of teeth on a tool. Each tooth is higher than the previous one, removing more material with each pass. Broaching produces finished parts in a single stroke and is used to create internal and external features with high tolerances. Spline broaching specifically uses broaching tools with teeth arranged to cut spline profiles on gears or other components. It allows roughing and finishing internal splines in one pass at high production rates.

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Faraz Ishani
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© Attribution Non-Commercial (BY-NC)
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576 views

Spline Broaching

Broaching is a machining process that removes metal using a row of teeth on a tool. Each tooth is higher than the previous one, removing more material with each pass. Broaching produces finished parts in a single stroke and is used to create internal and external features with high tolerances. Spline broaching specifically uses broaching tools with teeth arranged to cut spline profiles on gears or other components. It allows roughing and finishing internal splines in one pass at high production rates.

Uploaded by

Faraz Ishani
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Broaching

Broaching
• Broaching is the process of removing metal with
a tool which has “teeth” arranged in a row. Each
tooth is successively higher than the previous
tooth and removes more material. In broaching,
one stroke or cycle of the machine produces a
finished part.
• Broaching is used to produce both internal and
external features. Production rates are high and
tolerances of +/- .0005” are possible.
Broaching
Broaching
Broaching
An
hydraulic
vertical
type
broaching
machine
Purpose of Broaching
Broaching is done when the profile of the
work piece cannot be achieved by normal
conventional machining processes

Broaching can be done both externally as


well as internally
Various
types of
broaches
Spline Broaching
Spline broaching:

As the name states spline broaching is used to make


internal splines on the gears or blanks. For
broaching of either straight sided spline or involute
spline, regular spline broaches are used. Straight
sided splines can be broached by normal key way
broaching procedure when the quantity of broaching
is small.
Types of profiles that a spline broach can form
A spline broach
For small quantities the spline broach resembles
the key way broach; except the top side will be
reduced corresponding to that outside the mating
shaft.
The regular spline broach design is like that of a
round broach, with teeth gradually increasing in
diameter until the final broach is reached. All
cutting is done outside diameter and not the sides
of the teeth.
Prior to broaching, a minor pre finished hole is
required. How ever if close concentricity is
required between minor and major diameters a
combination broach can be used.
The finishing spline teeth are of the same
diameter, but the first 3 to 4 take a light cut and
the final 3 to 4 finish the hole.
Spline Broach Tool

Splines broached
Broaching
Tool Feed Direction
Gullet Tool

Depth of
cut per tooth

Workpiece
Advantages & Disadvantages
– Advantages
• Rough to finish in one pass
• Production rates are high
• Cutting time is quick
• Rapid load and unload of parts
• Any form that can be produced on a broaching tool
can be produced
• Production tolerances are excellent
• Operator skill is low
Advantages & Disadvantages
– Disadvantages
• Tooling cost can be high
• In some cases--not suited for low production rates
• Parts to be broached must be strong enough to
withstand the forces of the process
• Surface to be broached must be accessible
• The spline broach tool itself is very expensive
• Broaching cannot be done for lengths more than 3
meters
Some pictures showing
spline broaching
A spline component
Broach tool

Splines on the tool

Rings used in the gear box which have


splined profile which are directly
mounted on the spline shaft which
transmits motion on the gears.
A Spline broach tool

The splines are located in


helical pattern on the tool
A vertical
broaching
machine
Various spline broaching tools
Spline broach inserts
A spline component
Spline broach nomenclature

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